Roll-forming machine



A ril 14, 1964 -r. J. BOTTOM ROLLFORMING MACHINE 2 Sheets-Sheet 1 Filed Feb. 27, 1961 INVENTOR THEODORE J. BOTTOM BY (MW M W ATTORNEYS April 14, 1964 T. J. BOTTOM ROLL-FORMING MACHINE 2 Sheets-Sheet 2 Filed Feb. 27, 1961 ATTORNEYS United States Patent Oil 3,128,818 Patented Apr. 14, 1964 ice 3,128,318 ROLL-FQRMHNG MACHINE Theodore J. Bottom, Kirlrwood, Mo. Aluma Kraft Mfg. Co., 1330 N. Rock Hiil Road, St. Louis 24, Mo.) Filed Feb. 27, 1961, Ser. No. 91,969 Claims. (Cl. 153-4) The present invention relates to a machine for the rollforming of sheet metal, and has particular reference to an improved machine for fabricating strips of sheathing material for buildings, such as roofing and siding. An important object of the invention is to provide an improved roll-forming machine for producing custom tailored sheathing strips at the building site where they are to be installed.

The production of length-to-order roofing and siding strips at the point of installation yields a number of important advantages over the prevailing system, wherein prefabricated strips are delivered to the job site, and there cut to the length needed to fit a particular portion of a wall or roof surface. That system results in considerable wastage of the strip material in the form of unusable shorts, and because of damage in transit and handling.

In the system made practical by the present invention a compact, readily portable roll-forming machine and a coil of the sheet metal stock are taken to the job site. The operator measures a building surface, sets an adjustable control device and puts the machine into operation. There results a custom tailored strip, ready for application without additional cutting or trimming. The improved method eliminates wastage, facilitates installation, and results in a superior job. Because strips of any desired length may be readily produced, and the length is not restricted to that which may be conveniently transported in a truck, many joints pervious to moisture may be eliminated.

Accordingly, an important object of the present invention is to provide an improved machine for on-the-site production of metal sheathing strips, custom-tailored to the building to which they are to be applied.

More specifically, an object of the invention is directed to the provision of a machine of the described character embodying improved control means to facilitate the production of formed strips of any desired predetermined length.

Yet another object is achieved in improved means for drawing the stock material from the supply roll and feeding it to the forming rolls of the machine, the operation of the said feeding device being coordinated with that of a stock cut-off device, all to the end of expediting the production of the strips, each of any desired length.

Other objects and advantages will appear as the description proceeds.

In the drawings:

FIG. 1 is a side view of a roll-forming machine embodying the present invention;

FIG. 2 is a top plan view of the assembly of operating components;

FIG. 3 is a side elevational view of the assembly shown in FIG. 2;

FIG. 4 is an elevational view of the cut-off device as viewed from line 4-4 of FIG. 3;

FIG. 5 is a fragmentary side elevational view of the limit switch assembly, and

FIG. 6 is a schematic wiring diagram.

Described generally, the operating components of the machine are mounted on a frame structure which desirably includes a pair of ground wheels 11 that enable the machine to be easily moved to a location close to the point where the product is to be installed, thus to minimize handling of the finished strips. The operating components of the machine include a number of sets of forming rolls 12a and 12b through which the stock material passes in consecutive order, each set of rolls adding a turn or bend to the strip as received from a preceding set of rolls, until the desired shape is finally accomplished, as is conventional procedure in roll-forming equipment. In the present example the machine is shown equipped with three sets of forming rolls which would be sufficient only for the production of strips of a relatively simple configuration. At one end of the unit there is provided a holder 13 for a coil 14 of sheet metal stock. The flat stock strip is drawn from the coil 14 by feeding means, comprising a feed roller 15 and a coacting pressure roller 16 which is movable toward and from the feed roller and serves in the manner of a clutch part to render the feed rolls effective or ineffective to advance the stock to the forming rolls. Before reaching the forming rolls the strip stock passes between the blades of a cutoff device indicated generally at 17, located between the feed ing device and the first set of forming rolls. As will be subsequently described, the cutoff mechanism 17 and the feed device are interconnected and their operations coordinated, the feeding device being rendered inoperative when the cutoff blade is moved into cutting relation to the stock.

The finished strip is discharged from the last set of forming rolls and into an elongated, channel-shaped receiver 18. The receiver 18 is detachable from the main body of the machine and is desirably made in readily assembled sections so that in transit the receiver may be conveniently carried separately, or on the side of the main body of the machine. Suitable legs 19 are provided for supporting the receiver 18 at appropriate points spaced from the machine body.

Receiver 13 is particularly characterized by the provision of a scale 21? that extends along the bottom of the channel. A limit switch SW3 carried by the receiver channel has a yieldable operating finger 2.2 that projects into the path of movement of the shaped strips. Switch SW3 with its operating finger is adapted to be adjustably positioned by clamping means 23 at any desired point along the receiver and is electrically connected by a flexible cable 24 into the operating and control circuit of the drive motor 25.

The limit switch SW1 is mounted on the under side of the receiver 18 and is adjustably secured by means of a screw and wing nut assembly 26, the said screw extending through the longitudinal slot 27 in the receiver member. The operating finger 22 of the limit switch also projects upwardly through the slot 27 where its upper end is in position to be engaged and moved by an on-coming strip. Scale 21} extends along slot 27 so that it is a relatively easy matter to adjust and fix the position of switch SW3 with the operating finger 22 adjacent an index mark on the scale. As will be more fully explained, the location of the switch SW3 along the receiver will determine the length of the strip produced in any particular cycle of operations. By changing the switch location between consecutive cycles, which may be readily accomplished, the strips formed during those cycles'will be of different length, each in strict accordance to the setting of the limit switch which is preferably of the quick-acting or so-called micro variety. It should also be noted that the operating finger 22 is such as to permit the work strip to ride over it when movement of the strip is caused to be resumed, following a stoppage, as will be explained.

Now described the parts of the machine in somewhat greater detail, the frame structure of the machine includes a pair of parallel, longitudinally extending bed rails 29 on which the roller assemblies are mounted. Each set of the forming rolls includes a lower roll 12:; and an upper,

companion roll 12b. The lower said rolls have shafts which are mounted in bearing blocks 30 fixedly secured to the bed rails 29. Bearings for the shafts 31 for the upper rolls 12b are slidably mounted, each on a pair of vertical guide posts 32 whose upper ends are securely anchored to a horizontal frame member 33. The upper said rolls are constantly urged toward the lower rolls by compression springs 34 that bear downwardly upon the movable bearing blocks for said rolls. The upper ends of the compression springs engage seat plates 35 having stem portions which are threaded and carry adjustment nuts 36, by which the spring force acting to press the upper roll toward the lower roll may be regulated. The upper and lower forming rolls are operatively connected together by gears 37, and adjacent lower gears are connected by intermediate gears 38 so that all of the forming rolls will rotate in unison. The work strip is supported centrally in its passage through the rolls by a longitudinally extending support bar 39.

The feed roll assembly 15, 16 is located near the forward end of the machine. The lower feed roll rotates in bearing blocks 40 which are rigidly secured to bed rails 29. A drive sprocket 41 on the feed roll 15 is connected to and driven by a sprocket 42 on one of the forming rolls, by means of drive chain 43.

The upper roll 16 is mounted in bearing blocks 44, slidable on vertical guide rods 45 for movement toward and from the lower feed roll 15. Compression springs 46 seated upon the upper sides of the bearing blocks 44 bear upwardly against adjustable pressure plates 47. These pressure plates have stem portions 48 which are acted upon by an eccentric shaft 49 journalled for rotation in suitable bearings carried on the upper frame members 33. A crank arm 50 fixed to a projecting end of the eccentric shaft is rotatable to produce downward displacement of the pressure plates 47 and compression of the springs 46. Compression springs 46 are relatively more rigid than springs 51 that extend between the bearing blocks for the upper and lower feed rolls and act to move the pressure roller 16 upwardly when it is relieved of the downward pressure of springs 46. It will be understood that upward displacement of the pressure roll 16 releases the work strip from the feed roll 15 and the latter is then free to rotate without advancing the work strip.

The cutoff device 17, located between the feeding rolls and the first set of forming rolls, comprises a fixed blade 52 that extends transversely below the work strip, the cutting edge of the blade being disposed substantially in the plane of the work strip. Blade 52 is mounted on standards 53 rigidly bolted to the bed rails 29. A movable cutoff blade 54 overlies the work strip and coacts with the fixed blade in the manner of a shear. The ends of blade 54 are secured to vertical slide rods extending through guideways formed in projecting lugs 56 on the standards 53. The slide rods are interconnected at their lowerends by a transverse tie bar 57. This tie bar is adapted to be forced downwardly by the short arm 58 of a lever system which includes the shaft 59, a hand lever arm 60, counterweight lever arm 61, and feed control lever arm 62. The lever arm 62 and the crank arm 50 which operates the feeder device control are interconnected by a rod 63-, such that operation of the cutoff device to sever the work strip causes movement to be transmitted through the lever arm 62, rod 63 and crank arm 50 to release the upper pressure roll 16. Consequently, there will be no movement of the work strip when the movable blade 54 is in a lowered, cutting position. Conversely, when the movable cutting blade is lifted out of the path of movement of the work strip the upper feed roll will descend and start movement of the work strip. Guide members 64 receive the side edges of the work strip, serving to direct the strip to the cutoff blades and to deliver the strip in a flat, horizontal condition to the first set of forming rolls.

The machine is driven by an electric motor assembly 65, mounted on a suitable carrier frame below the bed rails 29. The motor assembly includes speed reduction gearing leading to a drive sprocket 66 which is connected by a transmission chain 67 to a driven sprocket 68, fixed to one of the intermediate gears 38. The motor assembly also includes brake means, not shown, which function automatically to stop the motor quickly when it becomes deenergized. Geared motors equipped with automatic, quick-stop brake means of the character described are currently on the market and available to the trade.

The electrical supply and control circuit is illustrated in FIG. 6. The circuit includes a double-pole relay having a solenoid operating coil 70. One set of the relay contacts 71 are connected in series with the drive motor 25, so that closure of these contacts energizes the motor from supply lines L1 and L2. A momentary contact, normally open, starting switch SW1 controls the energization of the relay coil 70 through a circuit which includes conductor 69, relay coil 70, starting switch SW1, a normally closed stop switch SW2, and the contacts of the normally closed limit switch SW3. Coil 70 will remain energized after the start button of switch SW1 is released, conductor 72 providing a by-pass for relay contacts 73. Connected in shunt relationship with the limit switch SW3 is a normally open switch SW4. That switch has a push button 8!! arranged below the transverse tiebar 57 of the cutoff device. Descending movement of the said tiebar during a shearing operation causes SW4 to close and to remain closed until the tiebar is raised. Operation of the cutoff device thusly closes switch SW4, enabling the motor to be re-started even though limit switch SW3 is in open condition.

The function and operation of the limit switch SW3 has been previously touched upon. After its position has been fixed on the receiver runway to accord with the desired length of a strip, and the motor 25 started by switch SW1, the machine will continue to operate until the motor circuit is broken at limit switch SW3, as a result of the engagement of the forward end of the work strip against the operating finger 22 of limit switch, causing that switch to open. The brake device associated with motor 25 acts quickly to arrest advancement and the strip, which may be stopped with less than of an inch overrun. Thereafter, the cutoff device is operated by the manual lever 60. This severs the strip, closes switch SW4 and releases the unformed stock strip from the feed rolls 15 and 16. The starting button is again actuated to restart the motor, the circuit for relay coil 70 being established through SW4 that provides a bypass around the open limit switch SW3. Thus the previously unfinished tail portion of the work strip is caused to pass completely through the forming rolls. The completed article may then be removed from the runway and the machine is ready to form another one. The feeder rolls will not reengage the work strip to advance the same to the forming rolls until the movable cutoff blade is raised.

Having described my invention, I claim:

1. A machine for roll-forming sheet metal stock to produce elongated shaped elements of various lengths, including forming rolls, a feeder roll for advancing flat strip stock material to said forming rolls, a drive motor, transmission means connecting said drive motor to said forming and feeder rolls, clutch means associated with said feeder roll, manually operable to render said feeder roll ineffective to advance the stock material to forming rolls, cutoif means for the stock material located and fixed between said forming and feeder rolls, including a blade element movable into and out of cutting relation to the stock material, and means operatively connecting said blade element and said feeder roll clutch means for rendering said feeder roll ineffective to advance the stock material when said blade element is moved into cutting relation with the stock material.

2. A roll forming machine as defined in claim 1 in cluding an elongated receiver for the shaped elements, extending from the forming rolls, a supply and control electric circuit for said drive motor, said circuit including a motor-deenergizing limit switch having a projecting operating member, and means adjustably positioning said switch along said receiver at predetermined distances from said cutolf means with said switch operating member disposed in the path of movement of shaped elements discharged from said forming rolls for engagement thereby so as to actuate said limit switch.

3. A roll forming machine as defined in claim 2, wherein said motor supply and control circuit includes a second switch connected in shunt relation to said limit switch, said second switch being operated by said cutoff means to recondition the circuit to energize the drive motor when said cutolf blade is in cutting relation to the stock material so as to move the severed length of stock material completely through the forming rolls.

4. In a roll forming machine of the character described, including forming rolls, a feeder roll for advancing unshaped stock material to said forming rolls, a cutoff device located and fixed between said feeder and said forming rolls, including a blade and means mounting said blade for movement into and out of cutting relation with the unshaped stock material, a drive motor, transmission means connecting said motor to said feeder and forming rolls, clutch means for rendering said feeder roll ineffective to move the stock material, means interconnecting said clutch means and said blade to render said feeder roll ineffective when said blade is in cutting relation with the stock material, an electric supply and control circuit for said motor, said circuit including a normally closed limit switch for deenergizing the drive motor when opened, said limit switch having an actuating member arranged to coact with the stock material to open said switch when a predetermined length of stock has been passed by the cutoff device, and a second switch operable to circumvent said limit switch to enable energization of said drive motor when said limit switch is open to move the severed length of stock material completely through the forming rolls while the feeder roll is ineffective.

5. A roll forming machine as defined in claim 4, wherein said second switch operates in conjunction with said cut-off blade to establish a circuit around said limit switch when said blade is in cutting relation to the stock material to move the severed length completely through said forming rolls.

References Cited in the file of this patent UNITED STATES PATENTS Re. 18,715 Hutchinson Jan. 17, 1933 1,925,845 Moore Sept. 5, 1933 2,295,953 King Sept. 15, 1942 2,353,925 Pattison July 18, 1944 2,364,716 Huebner et al. Dec. 12, 1944 2,708,958 Crafton May 24, 1955 

1. A MACHINE FOR ROLL-FORMING SHEET METAL STOCK TO PRODUCE ELONGATED SHAPED ELEMENTS OF VARIOUS LENGTHS, INCLUDING FORMING ROLLS, A FEEDER ROLL FOR ADVANCING FLAT STRIP STOCK MATERIAL TO SAID FORMING ROLLS, A DRIVE MOTOR, TRANSMISSION MEANS CONNECTING SAID DRIVE MOTOR TO SAID FORMING AND FEEDER ROLLS, CLUTCH MEANS ASSOCIATED WITH SAID FEEDER ROLL, MANUALLY OPERABLE TO RENDER SAID FEEDER ROLL INEFFECTIVE TO ADVANCE THE STOCK MATERIAL TO FORMING ROLLS, CUTOFF MEANS FOR THE STOCK MATERIAL LOCATED AND FIXED BETWEEN SAID FORMING AND FEEDER ROLLS, INCLUDING A BLADE ELEMENT MOVABLE INTO AND OUT OF CUTTING RELATION TO THE STOCK MATERIAL, AND MEANS OPERATIVELY CONNECTING SAID BLADE ELEMENT AND SAID FEEDER ROLL CLUTCH MEANS FOR RENDERING SAID FEEDER ROLL INEFFECTIVE TO ADVANCE THE STOCK MATERIAL WHEN SAID BLADE ELEMENT IS MOVED INTO CUTTING RELATION WITH THE STOCK MATERIAL. 